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D40

HINGE # 1017

2 x Support Plate 1018

8 x M8 Bolt

8 x M8 Washer

6 x M6 20mm Bolts

6 x M6 Washers

20 x Screws

2 x Lid mount gas strut bracket 1041

2 x Self tap strut mount 1040

2 x Lock bracket 1072

2 x Gas struts (250N)

1 x Alcohol wipe

1 x Instruction manual

1 x FBA Bar

Fitting kit made by :

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• Pen / Marker • Die Grinder & multi tool • Soapy water solution • Centre Punch • Masking Tape • Allen Key set (Metric) • Drill & Drill bits • Scissors & Knife • Phillips head screwdriver • Ruler • Caulking Gun • Spanner & Socket • Silicon - Non Acetic • Tape measure

• Read Instructions fully before commencing installation. • Clean Tonneau Cover with a mild detergent and water solution • Do not use abrasive cleaners or solvents • Refer to manufactures instructions applicable to power drill. • Protect Tub floor against scratches during installation process.

Check contents of kit before commencing fitment and report any discrepancies

Fitting Instructions Part Number D40 Nissan D40 Navara

Dual Cab 2007+

If lubrication of the locks or hinges is required use only Graphite Powder. DO NOT use any other lubricants or oils.

• Do not stand/sit or rest heavy objects on Tonneau Cover • Humans or animals are not to be under the closed Tonneau at any given time • Securely lock tonneau Cover before operating vehicle • Tonneau Cover is not dust or water tight • Do not carry open volatile chemicals with Tonneau Cover installed • If contact with volatile chemicals occur, clean Tonneau with mild detergent and water solution

Tools Required

Maintenance

Care Instructions

IMPORTANT

Parts List Qty Pre-Fitted

Hard Tonneau Cover 1

Gas Struts (250N) 2

Front Hinge 2

Hinge Support Plate 2

M8 Washer 8

M8 Bolt 8

Lock Bracket 2

Self Drilling Screw 13

Lid Strut Bracket 2

M6 Washer 6

M6 Bolt 6

Front Body Attach Bracket 2

Front Body Assembly Bar 1

Lock Set 2

Tonneau Corner Pieces 2

Cleanseal 1

*Image example shown only

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Installation Steps Flow Chart

START

TUB PREP FOR LID INSTALL

LID INSTALL AND ADJUSTMENT

FINISH

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Thoroughly clean installation areas. Lay a sheet inside the tub to catch metal drill swarf from installation.

Important:

Instructions are for Utes with an UNDER-RAIL tubliner. If you have an OVER-RAIL tubliner you must trim the top off.

The Front Bar Assembly (FBA) should be fitted first. The FBA will already have the hinges fitted to it. Align the bar along front of tray, ensuring ends of bar are flush with sides of tray. Remove white paper tape from rubber seal and attach the FBA using self-drilling screws (supplied) through holes pre-drilled in bar. Apply clear or black silicone to any gaps and between the FBA and the vehicle to pre-vent water entry.

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Gas Struts: Hook tape measure over front edge of tub, measure along top edge of tray 1010 mm (windscreen end) then down 25mm and mark the screws position for the gas strut bracket. Position the gas strut bracket accordingly, mark two mounting holes and centre. Refer to Fig. 1 and Fig. 2

1010 mm

Fig.1 - Gas strut bracket location

25 mm

Fig.2 - Gas strut bracket location

Using a 2 mm diameter drill bit set to 5 mm drill stop. Drill two pilot holes. Attach small gas strut bracket using self drilling screws provided. Repeat process on other side of tray. Refer to Fig. 2 and Fig.3

Fig.3 - Gas strut bracket fitment

Attach small shaft end of gas strut onto gas strut brackets, by clicking them in place. Refer to Fig.4 with regard to gas strut orientation.

Fig.4 - Gas strut orientation

Fig. 5- Hard Cover strut bracket location

With the lid on the floor and taking care to prevent damage or scratches to the painted surface, fit the upper gas strut mounting brackets to the lid using 20mm M6 Screws and Washers. Refer to Fig. 5

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Important: DO NOT over tighten screws. Recommended tightening torque is 1- 3 Nm

With one person on each side, lift lid to the vertical position and insert the hinge tongues into the hinge slots on the front bar assembly. Refer to Fig. 6 and Fig. 7

Fig. 7- Hard Cover strut bracket location Fig. 6 - Lift Lid near vertical and carefully

slide hinge tongues into hinge slots.

Important:

Ensure tongues are fully inserted into the hinge slots.

Check clearance of tonneau cover to vehicle rear corners. Ensure the tailgate is open and close tonneau cover. Check clearances at both rear corners between tonneau cover and sheet metal. Gaps should be consistent. If tonneau cover is touching sheet metal or gaps are not even, adjustment of the tonneau position may be required.

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With the Hard Tonneau Cover opened, attach the cylinder end of each gas strut onto the mounting brackets attached to the Hard Tonneau Cover by clicking into place. Refer to Fig. 9

Fig. 9 - Attach gas strut

Important:

If you have purchased a Central Locking Ute Lid please ignore the next page concerning Lock Bracket Installation and Lock Bracket adjustment.

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Important: This page for Manual Locking lids ONLY

Please skip this page if you have purchased a Central Locking Lid

Fig. 11 - Install lock bracket

Close the Hard Tonneau Cover and try the locks. You may need to adjust the lock brackets on the Ute tub up or down. When correctly adjusted, you should need to apply slight pressure to the lid in order to operate the locks. Refer to Fig. 12.

Fig. 12 - Lock bracket adjustment

Important: Excess tension could damage the lock.

Lock Brackets: To fit lock brackets, open tailgate and close the Hard Tonneau Cover. Make a mark where the lock cam (arm) lines up with the sides of the tub. Open Hard Tonneau cover and locate the two pairs of bolts on either side of the tub near the tailgate. Remove the rear bolt and place striker hinge - aligning the middle hole with the bolt hole and re-bolt. Ensure that there is allow-ance for up and down adjustment of the bracket. Repeat on other side. Refer to Fig. 11

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Having trouble? Call your Supplier.

NOTE: Please ensure Lid is kept locked at all times when not being used, for both safety and longevity.

Paint care instructions:

Your new painted Hard Tonneau Cover has been covered with a plastic film to protect the paint from damage. It will require cleaning and possibly light polishing after the protective film has been removed. Use polish as per new paint on a new vehicle. Wash Hard Tonneau Cover using water and normal carwash detergent and polish with an automo-tive polish.

Fig. 9 - Remove gas strut

Important: To remove the Hard Tonneau Cover from the vehicle, detach the gas struts from the Hard Tonneau Cover. This is done by inserting a small screwdriver under the metal spring clip on the strut and easing it out sufficiently to allow the strut to be popped off the ball (Refer to Fig 9). From inside of tub , remove 4 bolts from each hinge bracket. Ensure someone is supporting the lid when detaching. Never completely remove the metal spring clip from the gas strut end, and never force the strut off the ball.